Handtool and method for solderless electrical connections

ABSTRACT

This disclosure relates to a handtool for initially crimping a ductile, fracturable electrical connector to a pair of conductor wires disposed in openings in the connector in order to form an electrical connection to the wires. The tool is provided with a mandrel which is adapted to engage an additional opening in the connector during the initial crimping operation in order to maintain the additional opening free to receive another wire, post or other electrical connection to be fastened to the connector in a final crimping operation at a later time.

United States atet Inventor Richard J. Wunder Richboro, Pa.

Appl. No. 881,776

Filed Dec. 3, 1969 Patented Jan. 11, 1972 Assignee Thomas & Betts Corporaton Elizabeth, NJ.

HANDTOOL AND METHOD FOR SOLDERLESS ELECTRICAL CONNECTIONS 10 Claims, 9 Drawing Figs.

US. Cl 72/410,

4 29/203 H Int. Cl 821d 9/08 Field of Search... 72/409,

410; 29/203 11, 203 I-iC E 1 2 121 212 D, 243.56, 282, 280, 630 A, 630 B References Cited UNITED STATES PATENTS 3/1971 Erhardt, Jr.

3,470,728 10/1969 Polidori 72 410 3,398,445 8/1968 Westendorfetal. 29/203H 3,115,797 12/1963 Howe 29/282 3,328,871 7/1967 Over 29/280 3,157,075 11 1964 Filia 29/20311 1,228,735 6/1917 Anthony 29/243.52

Primary Examiner-Charles W. Lanham Assistant ExaminerMichael J. Keenan Attorney-Thomas M. Marshall ABSTRACT: This disclosure relates to a handtool for initially crimping a ductile, fracturable electrical connector to a pair of conductor wires disposed in openings in the connector in order to form an electrical connection to the wires. The tool is provided with a mandrel which is adapted to engage an additional opening in the connector during the initial crimping operation in order to maintain the additional opening free to receive another wire, post or other electrical connection to be fastened to the connector in a final crimping operation at a later time.

IIANDTOOL AND METHOD FOR SOLDERLESS ELECTRICAL CONNECTIONS BACKGROUND OF THE INVENTION 1. Field of the Invention The field of this invention is electrical connectors for conductor wiring. This invention relates to an apparatus and method for forming an electrical and mechanical connection between a pair of conductor wires and a specially designed electrical connector. More particularly, this invention relates to a handtool and method used to cold form an electrical and mechanical connection between a pair of conductor wires and a specially designed electrical connector without the use of solder. Still more particularly, this invention relates to a portable handtool and method for crimping a ductile, fracturable connector to a pair of conductor wires in such a manner that an aperture in maintained in the connector so that at a later time a second electrical and mechanical connection can be made to another conductor wire or post in a second crimping operation.

2. DESCRIPTION OF THE PRIOR ART U.S. Pat. applications Ser. No. 648,795, filed June 26, 1967 and Ser. No. 792,225, filed Jan. 14, 1969 (as a continuation of Ser. No. 555,745) relate to a connector for forming an electrical and mechanical connection between a pair of wires and a connector.

SUMMARY OF THE INVENTION The handtool used in this invention is in some respects related to a pair of pliers, but with significant modifications and improvements thereover. The tool is used to grasp a specially designed electrical connector which is made of a ductile metal. The conductor wires to be fastened to the connector are inserted into spaces on the outer edge of the connector. A mandrel, which is part of the handtool, is then fitted into an aperture in the center of the connector. Then the handtool is used to squeeze the connector and crimp it to the conductor wires while maintaining the integrity of the aperture into which the mandrel has been fitted. The result of this operation is that the conductor wires are fastened to the connector and the connector can at a later time be fastened to another wire or electrical post disposed in the aperture by means of a second crimping operation. The fracturable quality of the metal connector allows it to be broken away from the other electrical components whenever disassembly is required such as after the first crimping operation or after the second crimping operation without damaging the other electrical components.

Accordingly, it is an object of this invention to provide a handtool which is light, portable, inexpensive to manufacture, easy to use and which can be carried on the person of a technician or mechanic.

It is another object of this invention to provide a handtool for making a solderless electrical connection between a connector and an electrical conductor.

It is another object of this invention to provide a method for making a solderless electrical connection between a deformable and ductile connector and a pair of electrical conductors.

It is another object of this invention to provide a means for making a solderless electrical connection which can be easily broken without destroying or rendering useless the electrical wiring involved.

It is still another object of this invention to provide a handtool which applies crimping action in the form of two diametrically opposed forces acting along paths which form a straight line, as distinguished from the force applied by the ordinary pliers which force acts along a path in the shape of an arc.

These and other objects and advantages of the invention will become more apparent from the following detailed description, the accompanying drawings and the claims.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. I is a perspective view of one side portion of the apparatus of the invention, the handtool.

FIG. 2 is an enlarged fragmentary view of FIG. 1 illustrating the specially designed electrical connector which is intended to fit between the jaws of the handtool, and in addition, the ends of a pair of conductor wires which are intended to he crimped to the connector.

FIG. 3 is an enlarged fragmentary perspective view showing the opposite side portion of the handtool from that shown in FIGS. 1 and 2 and a button for operating the mandrel.

FIG. 4 is a fragmentary elevational view of the end portion of the handtool as shown in FIGS. 2 and 3 and again shows the button for operating the mandrel.

FIG. 5 is an enlarged fragmentary perspective view of FIG. 1 showing the jaws of the handtool adjacent to a connector before crimping.

FIG. 6 is an enlarged fragmentary perspective view showing the jaws and connector of FIG. 5 during the crimping opera tion.

FIG. 7 is an enlarged fragmentary perspective view showing the jaws and connector of FIG. 5 after the crimping operation has been completed but before the mandrel has been removed.

FIG. 8 is an enlarged fragmentary perspective view showing the jaws and connector of FIG. 7 after the rnandrel has been removed.

FIG. 9 is an enlarged perspective view showing the connector after the first crimping operation has been completed with a pair of conductor wires crimped to the connector.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to FIG. 1, the handtool is designed to be gripped by the human hand at the handles 12. By use of a pivoting mechanism, the action of squeezing the handles 12 together cases the jaws 14 of the handtool to move toward one another. The path along which these jaws 14 move is substantially a straight line, as distinguished from the path along which comparable components of the conventional pliers move which is substantially an arc. The jaws 14 thereby apply compressing forces which are diametrically opposed to one another.

Referring to FIG. 2, the jaws 14 of the handtool are designed so that a connector 16 can be placed between the jaws 14 when the jaws are in their open position as shown in FIG. 2.

Referring to FIG. 5 the connector 16 has openings, that is openings or recesses 16a, disposed adjacent its outer edges into which the ends of a pair of conductors 18 may be inserted. The connector used with this embodiment is of a substantially elliptical shape with the recesses 6a provided for the conductors 18 being disposed opposite one another and along the longer axis of the ellipse. The connector 16 is also provided with an aperture 20 in substantially the center of the connector.

Referring to FIG. 2, there is provided a mandrel 22 which is designed to fit into the central aperture 20 of the connector 16, shown in FIG. 5.

Referring to FIG. 3, the mandrel 22 may be moved in and out from between the jaws 14, independently of the action of squeezing the handles 12 shown in FIG. 1. The mandrel 22 is moved in and out by depressing a button 24 (FIG. 13) which causes the arm 26 connected to the mandrel head 28 to pivot about rod 30. Because of the spring 32 the mandrel is always biased in the position in which it is fully inserted between the aws.

FIG. 2 illustrates the at rest" position of the mandrel 22 when it is fully advanced between the jaws. FIG. 4 also illustrates the at rest" position of the mandrel mechanism. The spring 32 is in its normally extended position. Pressing on the button 2d causes the mandrel head 28 and the mandrel to which it is attached to be withdrawn from between the jaws. When pressure is removed from the button 24, the spring 32 causes the button 24 to return to its at rest position as shown in FIG. 4 in which the mandrel is fully inserted between the jaws.

FIGS. 5, 6, 7 and 8 show the successive stages of operation of this tool in crimping connector 16 to a pair of wires 8. Referring to FIG. 5, the connector 16 has been placed between the jaws 14 of the handtool with aperture 20 of the connector 16 engaged with mandrel 22. Each of the jaws 14 is provided with a notch 24 of substantially N-shape. The ends of a pair of wires 18 have been inserted into recesses 16a on the outer edge of the connector 16. The connector 16 is composed of a ductile material which can be deformed by the handtool in the action of crimping the connector 16 to the ends of the wires 18. The notches 24 of the tool are designed to receive and partially enclose the C-shaped outwardly opening recesses 16a of the connector in order to be able to form the connector 16 around each of the wires 18 in the action of crimping the connector to the wires.

FIG. 6 illustrates the next stage in the crimping operation in which the handles 12 (FIG. 1) have been closed together thereby causing the jaws 14 to move toward one another and form the connector 16. The mandrel 22, being in its rest position, continues at this point to remain fully inserted into the central aperture 20 of the connector 16. The aperture 20 of the connector may be circular or rectangular and the mandrel 22 is shaped accordingly.

FIG. 7 shows the jaws 14 of the handtool after this crimping action has been completed. The jaws 14 have been opened by releasing the squeezing pressure on the handles 12 (FIG. 1

FIG. 8 shows the mandrel 22 being withdrawnfrom the aperture 20 of the connector 16.

Referring to FIG. 9, the result of this crimping operation by the hand tool is a connector 16 which has been crimped to the ends of a pair of wires 18. By virtue of the mandrel being in aperture 20 during the forming operation, the aperture remains open and in its original form which enables the aperture of the connector 16 at some time in the future to be fastened to another electrical component, eg a terminal post or another wire in a second crimping operation. The connector 16 is composed of a conductive material which is ductile and fracturable, such as a sintered powdered metal. lts ductility allows it to be readily deformed in the crimping operation. Its fracturability allows the connector 16 to be removed from the electrical components, the ends of the pair of wires 18, and whatever component is inserted into the aperture 20, without damaging these members.

This invention is capable of numerous modifications and many other embodiments, in addition to the preferred embodiment disclosed herein, all within the scope of the invention.

Iclaim:

l. A handtool for crimping an electrical connector to a conductor disposed in an opening in the connector while maintaining an aperture in the connector in a predetermined form comprising:

a. a pair of jaws movable relative to one another along a predetermined path for compressing the connector when disposed therebetween;

b. a pair of handles connected to said pair of jaws and adapted to be squeezed by the human hand to urge said pair of jaws together;

c. pivotal means connected to said pair of handles for converting squeezing forces applied to said pair of handles to compressing forces at said pair jaws; and

d. an elongated mandrel mounted with respect to said pair of jaws along an axis transverse to the predetermined path of said jaws, said mandrel adapted to extend between said jaws for insertion within the aperture of a connector in order to maintain the aperture or a predetermined form during the crimping of the connector to the conductor disposed in the opening in the connector.

2. A handtool in accordance with claim I in which said pivotal means is adapted to move said pair of jaws along substantially a straight line predetermined path during the operation of compressing the connector in order to apply compressing forces to the connector which are substantially 0pposite to one another. I

3. A handtool in accordance with claim I m which said mandrel is movably mounted with respect to said pair of jaws transverse to said predetermined path of said jaws for movement between an operative position in which said mandrel extends between said pair of jaws and an inoperative position in which said mandrel is disposed away from between said pair of jaws.

4. A handtool in accordance with claim 3 and further comprising means for moving the mandrel between the pair of jaws and said inoperative position.

5. A handtool in accordance with claim 4 in which said mandrel is pivotally supported with respect to said pair of jaws for movement with respect thereto and in which said means for moving the mandrel between the operative position between said pair of jaws and the inoperative position comprises:

a. a button connected to a portion of said mandrel which is removed from the position of said mandrel which is adapted to extend between said pair of jaws, said button being adapted to be depressed by a finger of the operator; and

b. a spring normally biasing said mandrel into the operative position between said pair of j aws.

6. A handtool in accordance with claim 1 in which at least one of said pair of jaws includes a notched position disposed in a facing relationship with the other of said pair of jaws, said notched portion being adapted to receive and to partially enclose the opening of the connector prior to the crimping and to form the portion of the connector adjacent the opening therein to the conductor during the crimping operation.

7. A handtool in accordance with claim 6 in which said notched portion in at least one of said pair of jaws includes a pair of surfaces converging inwardly with respect to one another from the outer surface of said one of said pair of jaws which faces the other thereof, said surfaces of said notched portion intersecting one another along a line which extends substantially parallel to the pivotal axis of said pivotal means.

8. A handtool in accordance with claim 6 in which each of said pair of jaws includes one of said notched portions, said notched portions being disposed substantially opposite to one another in a facing relationship.

9. A hand tool in accordance with claim 1 and further comprising:

a. means connected to saidpair of handles for supporting said pair of jaws with respect thereto;

b. means mounted on said supporting means for guiding said pair of jaw members for movement with respect to one another along a common line of travel; and

c. means for articulating said. pair of jaws to said pair of handles.

10. A method of employing a hand crimping tool to crimp an electrical connector to a conductor disposed in an opening in the connector while maintaining an aperture in the connector in a predetermined form comprising the steps of:

a. placing the connector within the crimping portion of the hand crimping tool, the connector having a conductor disposed in the opening in the connector;

b. inserting a mandrel movably mounted with respect to the hand crimping tool into the aperture in the connector while the connector is within the crimping portion of the hand crimping tool;

c. crimping the connector to the conductor disposed in the opening therein while the mandrel is inserted in the aperture therein, the mandrel maintaining the aperture in a predetermined form during the crimping of the connector to the conductor; and

d. removing the mandrelfrorn the aperture to enable the crimped connector and the conductor crimped therewith to be removed from the tool.

UNITED STATES PATENT OFFICE CERTIFICATE OF "CORRECTION Patent 3 3 00 Dated January 11, 1972 Inventor(s) Richard J. Wunder It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Column 2, line 61, "(FIG.' 13)" should be (FIG. 3)

Column 3, line 6, "N-shape." should be V-shape.

Column 3,lineo 21, after "The" insert ceptral Signed and sealed this 6th day of June 1972.

(SEAL) Attest:

EDWARD M.FLEICHER,JR. ROBERT GOTTSCHALK Commissioner of Patents Attesting Officer FORM P0-1 0 (1 uscoMM-Dc 60376-5 69 U,S. GOVERNMENT PRINTING OFFICE: I969 O366-334 

1. A handtool for crimping an electrical connector to a conductor disposed in an opening in the connector while maintaining an aperture in the connector in a predetermined form comprising: a. a pair of jaws movable relative to one another along a predetermined path for compressing the connector when disposed therebetween; b. a pair of handles connected to said pair of jaws and adapted to be squeezed by the human hand to urge said pair of jaws together; c. pivotal means connected to said pair of handles for converting squeezing forces applied to said pair of handles to compressing forces at said pair jaws; and d. an elongated mandrel mounted with respect to said pair of jaws along an axis transverse to the predetermined path of said jaws, said mandrel adapted to extend between said jaws for insertion within the aperture of a connector in order to maintain the aperture or a predetermined form during the crimping of the connector to the conductor disposed in the opening in the connector.
 2. A handtool in accordance with claim 1 in which said pivotal means is adapted to move said pair of jaws along substantially a straight line predetermined path during the operation of compressing the connector in order to apply compressing forces to the connector which are substantially opposite to one another.
 3. A handtool in accordance with claim 1 in which said mandrel is movably mounted with respect to said pair of jaws transverse to said predetermined path of said jaws for movement between an operative position in which said mandrel extends between said pair of jaws and an inoperative position in which said mandrel is disposed away from between said pair of jaws.
 4. A handtool in accordance with claim 3 and further comprising means for moving the mandrel between the pair of jaws and said inoperative position.
 5. A handtool in accordance with claim 4 in which said mandrel is pivotally supported with respect to said pair of jaws for movement with respect thereto and in which said means for moving the mandrel between the operative position between said pair of jaws and the inoperative position comprises: a. a button connected to a portion of said mandrel which is removed from the position of said mandrel which is adapted to extend between said pair of jaws, said button being adapted to be depressed by a finger of the operator; and b. a spring normally biasing said mandrel into the operative position between said pair of jaws.
 6. A handtool in accordance with claim 1 in which at least one of said pair of jaws includes a notched position disposed in a facing relationship with the other of said pair of jaws, said notched portion being adapted to receive and to partially enclose the opening of the connector prior to the crimping and to form the portion of the connector adjacent the opening therein to the conductor during the crimping operation.
 7. A handtool in accordance with claim 6 in which said notched portion in at least one of said pair of jaws includes a pair of surfaces converging inwardly with respect to one another from the outer surface of said one of said pair of jaws which faces the other thereof, said surfaces of said notched portion intersecting one another along a line which extends substantially parallel to the pivotal axis of said pivotal means.
 8. A handtool in accordance with claim 6 in which each of said pair of jaws includes one of said notched portions, said notched portions being disposed substantially opposite to one another in a facing relationship.
 9. A hand tool in accordance with claim 1 and further comprising: a. means connected to said pair of handles for supporting said pair of jaws with respect thereto; b. means mounted on said supporting means for guiding said pair of jaw members for movement with respect to one another along a common line of travel; and c. means for articulating said pair of jaws to said pair of handles.
 10. A method of employing a hand crimping tool to crimp an electrical connector to a conductor disposed in an opening in the connector while maintaining an aperture in the connector in a predetermined form comprising the steps of: a. placing the connector within the crimping portion of the hand crimping tool, the connector having a conductor disposed in the opening in the connector; b. inserting a mandrel movably mounted with respect to the hand crimping tool into the aperture in the connector while the connector is within the crimping portion of the hand crimping tool; c. crimping the connector to the conductor disposed in the opening therein while the mandrel is inserted in the aperture therein, the mandrel maintaining the aperture in a predetermined form during the crimping of the connector to the conductor; and d. removing the mandrel from the aperture to enable the crimped connector and the conductor crimped therewith to be removed from the tool. 